Automotive vehicle HVAC rainhat

Abstract

In a preferred embodiment, the present invention provides a high temperature injection molded polymeric rainhat for a heating, ventilation, and air-conditioning air intake of an automotive vehicle is provided. The rainhat includes a flange for adhesively and sealably joining to a portion of the generally planar automotive vehicle cowling encircling a flared air inlet opening. A water dam joined to the flange extends beyond an end of the flared opening. The water dam has an extreme upper edge forming an opening. A foreign matter ingestion preventer has a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening. Each first support has opposite ends joined with the water dam, and each first support has a middle portion domed above the opening of the water dam. Each first support has a tapered exterior side. The foreign matter ingestion preventer also has plurality of second supports intersecting with the first curvilinear supports. Each second support has a middle portion being domed above the water dam. Each second support has a tapered exterior side. A surface area of the foreign matter ingestion preventer minus the surface area defined by the transverse dimensions of the first and second supports is generally equal to or greater than the area defined by the opening of the upper edge of the water dam.

What is claimed is:  
     
       1. A high temperature injection molded polymeric rainhat for a heating, ventilation, and air-conditioning air intake of an automotive vehicle, the vehicle having a cowling with a generally planar surface, the planar surface encircling a flared opening in the cowling, the rainhat comprising: 
       a flange for adhesively and sealably joining to a portion of the generally planar surface encircling the flared opening;  
       a water dam integrally joined to the flange and extending therefrom, the water dam having an interior surface closely engaging the flared opening of the cowling and extending upwards beyond a vertical end of the flared opening, and the water dam having an extreme upper edge forming an opening; and  
       a foreign matter ingestion preventer, the foreign matter ingestion preventer having at least one first curvilinear support extending in a first direction over the water dam upper edge opening, each first support having opposite ends joined with the water dam, and each first support having a middle portion being domed above the opening of the water dam upper edge, each first support having the interior side and an exterior side with the exterior side being tapered, the foreign matter ingestion preventer having at least one second curvilinear support intersecting with the first curvilinear support, the second curvilinear support extending in a second direction over the flared opening, and each second support having opposite ends joined with the water dam, and each second support having a middle portion being doomed above the opening of the water dam, each second support having an interior side and an exterior side with the exterior side being tapered, wherein a surface area of the foreign matter ingestion preventer minus the surface area defined by the transverse dimensions of the supports is generally equal to or greater than the area defined by the opening of the upper edge of the water dam.  
     
     
       2. A high temperature injection molded polymeric rainhat as described in  claim 1  with a plurality of first supports. 
     
     
       3. A high temperatures injection molded polymeric rainhat as described in  claim 2  with a plurality of second supports. 
     
     
       4. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein there is an axis of travel of airflow through the rainhat and the first and second supports form a rectangular image on a plane which is perpendicular to the axis of travel of airflow through the rainhat. 
     
     
       5. A high temperature injection molded polymeric rainhat as describe in  claim 1 , further including first rafters generally parallel to the first support, the first rafters extending in a first direction over the opening of the water dam edge, each first rafter having opposite ends joining with the water dam, with a middle portion being domed above the opening of the water dam upper edge and each first rafter having an interior side and an exterior side, with the exterior side being tapered, the first rafters intersecting with the second curvilinear supports wherein the area of the foreign matter ingestion preventer minus the surface defined by the transverse dimensions of the area of the first and second supports and first rafters is equal or greater to the area defined by the opening of the upper edge of the water dam. 
     
     
       6. A high temperature injection molded polymeric rainhat as described in  claim 1 , further including second rafters generally parallel to the second support, the second rafters extending in a second direction over the flared opening of the water dam upper edge, each second rafter having opposite ends joining with the water dam, with a middle portion being domed above the opening of the water dam upper edge and each second rafter having an interior side and an exterior side, with the exterior side being tapered, the second rafters intersecting with the first curvilinear supports and wherein the area of the foreign matter ingestion preventer minus the surface defined by the transverse dimension of the area of the first and second supports and second rafters is equal to or greater to the area defined by the opening of the upper edge of the water dam. 
     
     
       7. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the supports exterior surface is flush with the exterior surface of the upper edge of the rain dam. 
     
     
       8. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein an interior of the water dam has interior stops to make contact with an upper edge of the flared opening. 
     
     
       9. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the flange has descending therefrom a plurality of elongated fastener members with compliant barbed heads for insertion into prepared holes in the cowling to connect the rainhat with the cowling before the rainhat is adhesively joined to the cowling. 
     
     
       10. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the first and second rafters have an exterior which is flush with the exterior surface of the water dam. 
     
     
       11. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the first and second rafters have an interior which is flush with an interior surface of the water dam. 
     
     
       12. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein an interior surface of the water dam is tapered to an interior surface of the water dam to form an upper edge. 
     
     
       13. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein a heat expanding sealant is adhesively and mechanically joined to the flange. 
     
     
       14. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the rainhat is molded from Nylon. 
     
     
       15. A high temperature injection molded polymeric rainhat as described in  claim 1 , wherein the rainhat flange, water dam and foreign matter injection preventer are made in a single draw injection mold machine. 
     
     
       16. A high temperature injection molded polymeric rainhat for a heating, ventilation, and air-conditioning air intake of an automotive vehicle, the vehicle having a cowling with a generally planar surface, the planar surface encircling a flared opening in the cowling, the rainhat comprising: 
       a flange for adhesively and sealably joining to a portion of the cowling generally planar surface encircling the flared opening, the flange has descending therefrom a plurality of elongated fastener members with compliant barbed heads for insertion into prepared holes in the cowling to connect the rainhat with the cowling;  
       a heat expanding sealant adhesively and mechanically joined to the flange;  
       a water dam integrally joined to the flange and extending therefrom, the water dam having an interior surface closely engaging the flared opening of the cowling and extending upwards beyond a vertical end of the flared opening, and the water dam having an extreme upper knife edge forming an opening and an interior surface of the water dam is tapered to an exterior surface of the water dam to form the upper knife edge, and an interior surface of the water dam has interior stops to make contact with an upper edge of the cowling flared opening; and  
       a foreign matter ingestion preventer, the foreign matter ingestion preventer having a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening, each first support having opposite ends joined with the water dam, and each first support having a middle portion being domed above the opening of the water dam upper edge, each first support having the interior side and an exterior side with the exterior side being tapered, and the first supports exterior side being flush with the exterior surface of the water dam the foreign matter ingestion preventer having a plurality of second curvilinear supports intersecting with the first curvilinear supports, the second curvilinear supports extending in a second direction over the water dam, and each second support having opposite ends joined with the water dam, and each second support having a middle portion being domed above the opening of the water dam, each second support having an interior side and an exterior side with the exterior side being tapered and the second supports exterior side being flush with the exterior surface of the water dam, the foreign matter ingestion preventer further including first rafters generally parallel to the first supports, the first rafters extending in a first direction over the opening of the water dam, each first rafter having opposite ends joining with the water dam, each first rafter having a middle portion being domed above the opening of the water dam, each first rafter having opposite ends joining with the water dam, each first rafter having a middle portion being domed above the opening of the water dam and each first rafter having an interior side and an exterior side with the exterior side of the first rafter being tapered and the first rafter has ends flush with the exterior surface of the water dam, and the first rafter interior side being flush with an interior surface of the water dam, and the foreign matter ingestion preventer further including second rafters generally parallel to the second supports, the second rafters extending in a second direction over the opening of the water dam, each second rafter having opposite ends joining with the water dam, each second rafter having a middle portion being domed above the opening of the water dam and each second rafter having an interior side and an exterior side and the ends of the second rafter being flush with the interior and exterior surfaces respectively of the water dam, and the second rafter exterior side being tapered, the second rafters intersecting with the first curvilinear supports and rafters, and wherein the area of the foreign matter ingestion preventer minus the surface defined by the transverse dimensions of the area of the first and second supports and first and second rafters is equal or greater to the area defined by the opening of the water dam.  
     
     
       17. A high temperature injection molded polymeric rainhat as described in  claim 14 , wherein there is an axis of travel of airflow through the rainhat and the first and second supports project a rectangular image on a plane which is perpendicular to the axis of travel of airflow through the rainhat. 
     
     
       18. A high temperature injection molded polymeric rainhat as described in  claim 1  wherein the rainhat flange, water dam and foreign matter injection preventer are made in a single draw injection mold machine. 
     
     
       19. A single integral rainhat comprising: 
       
         a flange for adhesively and sealably joining to a portion of an automotive vehicle having a cowling;  
       
       
         a water dam integrally joined to the flange and extending therefrom, the dam further having an interior surface for closely engaging an automotive vehicle cowling, and an extreme upper edge forming an opening;  
       
       
         a foreign matter ingestion preventer joined with the water dam having a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening and a plurality of second curvilinear supports intersecting with the first curvilinear supports. 
       
     
     
       20. A rainhat as described in  claim 19 , wherein a surface area of the foreign matter ingestion preventer minus a surface area defined by the transverse dimensions of the first and the second supports is generally equal to or greater than an area defined by the opening of the upper edge of the water dam. 
     
     
       21. A rainhat as described in  claim 20 , wherein each first curvilinear support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       22. A rainhat as described in  claim 20 , wherein each second support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       23. A rainhat as described in  claim 20 , wherein there is an axis of travel of airflow through the rainhat and the first and second supports project a rectangular image on a plane which is perpendicular to the axis of travel of airflow through the rainhat. 
     
     
       24. A rainhat as described in  claim 24  wherein the flange adhesively and sealably joins to a portion of an automotive vehicle cowling having a generally planar surface encircling a flared opening, the cowling flared opening having a vertical end. 
     
     
       25. A rainhat as described in  claim 24  wherein the water dam interior surface closely engages the flared opening of the cowling and extends upwards beyond the cowling vertical end. 
     
     
       26. A rainhat as described in  claim 19  wherein the rainhat is formed from a high temperature injection molded polymeric material. 
     
     
       27. A rainhat as described in  claim 27  wherein the rainhat flange, water dam and foreign matter injection preventer are made in a single draw injection mold machine. 
     
     
       28. A rainhat as described in  claim 19 , wherein a heat expanding sealant is adhesively and mechanically joined to the flange. 
     
     
       29. A rainhat as described in  claim 26 , wherein the rainhat is molded from Nylon. 
     
     
       30. A single integral rainhat for a heating, ventilation, and air- conditioning air intake of an automotive vehicle, the vehicle having a cowling, the rainhat comprising:    
       
         a flange for adhesively and sealably joining to a portion of cowling;  
       
       
         a water dam integrally joined to the flange and extending therefrom, the water dam having an interior surface closely engaging the cowling and the water dam having an extreme upper edge forming an opening; and  
       
       
         a foreign matter ingestion preventer, the foreign matter ingestion preventer having a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening and a plurality of second supports intersecting with the first curvilinear supports. 
       
     
     
       31. A rainhat as described in  claim 30 , wherein a surface area of the foreign matter ingestion preventer minus a surface area defined by the transverse dimensions of the first and the second supports is generally equal to or greater than an area defined by the opening of the upper edge of the water dam. 
     
     
       32. A rainhat as described in  claim 31 , wherein each first curvilinear support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       33. A rainhat as described in  claim 31 , wherein each second support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       34. A rainhat as described in  claim 31 , wherein there is an axis of travel of airflow through the rainhat and the first and second supports project a rectangular image on a plane which is perpendicular to the axis of travel of airflow through the rainhat. 
     
     
       35. A rainhat as described in  claim 30  wherein the cowling has a generally planar surface encircling a flared opening, the cowling flared opening having a vertical end. 
     
     
       36. A rainhat as described in  claim 35  wherein the flange adhesively and sealably joins to a portion of the cowling generally planar surface encircling the flared opening. 
     
     
       37. A rainhat as described in  claim 35  wherein the water dam interior surface closely engages the flared opening of the cowling and extends upwards beyond the cowling vertical end. 
     
     
       38. A rainhat as described in  claim 31  wherein the rainhat is formed from a high temperature injection molded polymeric material. 
     
     
       39. A single integral rainhat for a heating, ventilation, and air- conditioning air intake of an automotive vehicle, the vehicle having a cowling, the rainhat comprising:    
       
         a flange for adhesively and sealably joining to a portion of cowling;  
       
       
         a heat expanding sealant adhesively and mechanically joined to the flange;  
       
       
         a water dam integrally joined to the flange and extending therefrom, the water dam having an interior surface closely engaging the cowling and the water dam having an extreme upper edge forming an opening; and  
       
       
         a foreign matter ingestion preventer for discouraging the entrapment of leaves or other articles which can clog up air intake openings, the foreign matter ingestion preventer having a plurality of first curvilinear supports extending in a first direction over the water dam upper edge opening and a plurality of second curvilinear supports intersecting with the first curvilinear supports. 
       
     
     
       40. A rainhat as described in  claim 39 , wherein a surface area of the foreign matter ingestion preventer minus a surface area defined by the transverse dimensions of the first and the second supports is generally equal to or greater than an area defined by the opening of the upper edge of the water dam. 
     
     
       41. A rainhat as described in  claim 40 , wherein each first curvilinear support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       42. A rainhat as described in  claim 40 , wherein each second support of the foreign matter ingestion preventer comprises: 
       
         opposite ends joined with the water dam, a middle portion domed above the opening of the water dam, and a tapered exterior side. 
       
     
     
       43. A rainhat as described in  claim 40 , wherein there is an axis of travel of airflow through the rainhat and the first and second supports project a rectangular image on a plane which is perpendicular to the axis of travel of airflow through the rainhat. 
     
     
       44. A rainhat as described in  claim 39  wherein the cowling has a generally planar surface encircling a flared opening, the cowling flared opening having a vertical end and wherein the water dam interior surface closely engages the flared opening of the cowling and extends upwards beyond the cowling vertical end. 
     
     
       45. A rainhat as described in  claim 39  wherein the rainhat is formed from a high temperature injection molded polymeric material. 
     
     
       46. A rainhat as described in  claim 45  wherein the rainhat flange, water dam and foreign matter injection preventer are made in a single draw injection mold machine.